Bag-lined spring core with monolithic perimeter, and reinforced and stabilized edges

ABSTRACT

A core of springs with monolithic perimeter frame and reinforced and stabilized edges, of the type used for the manufacture of seats for furniture or mattresses, which is comprised of: an arrangement of springs that can be manufactured from independent bag-lined cylindrical springs; and a layer of support material or bottom on which the arrangement of springs is arranged, the dimensions in length and width of said layer of support material being greater than those of the arrangement of springs, thereby generating a surplus of material around the arrangement of springs that supports, which is characterized in that; a monolithic perimeter frame of foamed material made in situ on the surplus material of the support layer, surrounds and reinforces the arrangement of springs, so that said perimeter frame is firmly joined as part of the chemical reaction of its foaming and adhesion process.

CROSS REFERENCE TO RELATED APPLICATION

This application takes the benefit of and claims priority from MexicanPatent Application Serial No. MX/u/2018/000062 filed on Feb. 2, 2018,the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present utility model is comprised within the field of spring corescomposed of a plurality of bag-lined springs used in the manufacture ofseats for furniture and mattresses, and in particular, it is related toa bag-lined spring core with reinforced and stabilized edges.

Description of the Related Art

Various proposals are known to date to increase the structural strengthof the terminal ends of a structure or core of springs, the foregoing,because experience has shown that the continuous use of a seat ormattress integrated from said structures or cores of springs quicklydeforms the perimeter zone of the seat or mattress in use, a conditionthat reduces its useful life, even though, in its central part, theaforesaid seat or mattress has optimal conditions of use.

Example of the proposals currently known to prevent prematuredeformation of the springs arranged in the periphery, either of astructure or core of springs that integrates a seat or mattress, isfound in the following documents.

U.S. Pat. No. 5,133,116 issued Jul. 28, 1992, wherein, Robert F. Wagner,disclosed a method for reinforcing and stabilizing an edge of spring, inparticular, using a continuous length of elastic cord or strap wedgedbetween turns of adjacent springs, a plurality of turns of said elasticcord or strap having around the perimeter of the set of springs.

In the patent MX 215,110 granted on Jul. 8, 2003 to Ohio MattressCompany Licensing and Components Group, under the title “Internalmattress wall structures interlocked with the assembly of internalsprings of the mattress”, an Invention was unveiled. Refers to aninternally enclosed mattress wall structure engaged with coils of aninternal mattress springs assembly to serve as an internal elasticstructural component of a mattress, the wall structure characterized inthat it comprises: a main body section having a generally flat wallsurface, upper and lower surfaces intersecting the wall surface, aseries of parallel flanges extending laterally of the main body sectionaway from the wall surface and adapted to be inserted between the turnsof the perimeter spirals of a assembly of internal springs, each of thetabs it is spaced apart from the adjacent flanges and has end sectionsadapted for mechanical engagement with the turns of the perimeterspirals of an internal spring assembly, an edge rising from the upperand lower surfaces to a point laterally inward of the surfaces of wall,the flat wall surface of the wall structure is adapted to be placed at aperimeter of an assembly of internal springs wherein the edge of theupper and lower surfaces of the main body is positioned and adapted tobe partially overlapped by spirals of an assembly of internal mattresssprings such that the edge is positioned inwardly of an outer extensionof the perimeter spirals, and the wall surface is adapted to extend atleast from the upper part of the assembly of internal springs to thelower part of the assembly of internal springs to serve as a structuralwall of a mattress.

In U.S. Pat. No. 5,210,890 dated May 18, 1993, John E. Hagglunddisclosed a mattress base including upper and lower frame sections thatare elastically interconnected and supported by a combination of springsand foam. In different embodiments of this invention, the springs are ofthe type: helical, torsional, torsion spring modules or a combinationthereof. In another embodiment, the foam comprises an elongated piece offoam that extends peripherally around the base and wraps or coats thesprings. The foam is softened in a pattern to receive portions of thesprings. Alternatively, the foam comprises discrete blocks of foamspaced around the periphery of the base and between select pairs ofadjacent springs.

U.S. Pat. No. 3,822,426 dated Jul. 9, 1974, owned by Sealy Incorporated,disclosed an upper pad and edge stabilizer for interior mattress springsunits, comprising a unitary member of resilient material having a padportion of mattress cover, and a portion of edge stabilizer. The upperpad portion covers the top or bottom of the spring unit. The edgestabilizer portion is inserted between at least one turn of each springin the outer row of the spring unit to harden the action of said spring.In one embodiment of this invention, the edge stabilizer portion ispreformed into the position it will assume on the mattress. In a secondembodiment, the edge stabilizer portion is formed such that it must bebent 90° to be in the position it will assume on the mattress.

And finally, in the patent MX 352,312B dated Nov. 17, 2017, immediateantecedent of the utility model object of the present description, it isdisclosed and protected in favor of Industrias Spum S.A. de C.V., a coreof springs with monolithic perimeter frame, which is comprised of: anarrangement of springs; a band of retention and insulation thatsurrounds the arrangement of springs whose height is coincident withthat of the arrangement and which prevents the foam material with whichthe monolithic perimeter frame is built in situ from penetrating intothe interior of said arrangement of springs.

Further details of the protected invention of the patent MX352,312B willbe presented in the detailed description section of the invention, theforegoing, in order to make it evident that the present utility modelresults from a technical modification of said invention, modificationthat brings with it substantial improvements in strength and stabilityat the edges of a core of springs with a monolithic perimeter frame.

As it is possible to warn of the teachings that arise from the state ofthe aforementioned technique, are various proposals that over time havesought to increase the structural strength of the edges of a coresprings used to make mattresses or other types of seats for furniture,however, the current known proposals refer to a mechanical connectionbetween the peripheral springs of an arrangement of springs and anindependent material such as elastic belts, or a structure of foamedmaterial previously formed and incorporated as an additional element tothe core or structure from which you want to integrate a mattress.

Unlike the known proposals, the present utility model achieves through amodification in the structure of the invention protected in the patentMX352,312B, integrating as the same elements the bag-lined perimetralsprings of the core of springs; and the monolithic perimeter frameformed in situ, thus giving rise to a “pocket spring core withmonolithic perimeter frame and reinforced and stabilized edges”, withwhich the following are intended:

SUMMARY OF THE INVENTION

An object of the present invention is to provide a bag-lined spring corewith reinforced and stabilized edges.

Another object of the present invention is to provide a bag-lined springcore with a monolithic perimeter frame.

Another object of the present invention is to provide a bag-lined springcore with a monolithic perimeter frame and reinforced and stabilizededges used in the manufacture of furniture or mattress seats.

Another objective of the present invention is to provide a bag-linedspring core with a monolithic perimeter frame and reinforced andstabilized edges, wherein said monolithic perimeter frame is made insitu from a foaming material.

Another objective of the present invention is to provide a bag-linedspring core with a monolithic perimeter frame and reinforced andstabilized edges, wherein said monolithic perimeter frame made offoaming material is attached to each of the bags containing theperipheral springs of the core, circumscribing them in at least aportion close to 50% of their circumference.

Another objective of the present invention is to provide a bag-linedspring core with a monolithic perimeter frame and reinforced andstabilized edges, wherein the union of the monolithic perimeter frameand each of the bags containing the peripheral springs of the core isachieved in a during the process of foaming and drying the foamingmaterial with which said perimeter frame is formed.

Still another object of the present invention is to provide a bag-linedspring core with a monolithic perimeter frame and reinforced andstabilized edges, wherein the union of the monolithic perimeter frameand each of the bags containing the peripheral springs of the coreallows to increase the resistance of the terminal ends of the springscore, to reduce the deformation effects that are generated with thecontinuous arrangement of loads on them, thus extending the useful lifeof furniture or mattresses manufactured from the proposed core.

The aforementioned objectives and others not mentioned, as well as thecharacteristic aspects and advantages of the proposed utility model,will be evident from the description and the figures that accompany itwith an illustrative and non-limiting character, and that are presentedbelow.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a conventional perspective of a core of springs withmonolithic perimeter frame used in the manufacture of seats forfurniture or mattresses, made in accordance with the invention protectedin the patent MX352,312B;

FIG. 2 shows a conventional perspective of an array of bag-linedindependent springs which forms an integral part of the protectedinvention in the patent MX352,312B, and which also forms an integralpart of the present utility model;

FIG. 3 shows a conventional perspective of an arrangement of threesealable bags joined together, from which the springs integrating thearrangement of springs of FIG. 2 are pocketed;

FIG. 4 shows a conventional perspective of an arrangement of threesprings bag-lined in sealed bags joined together, from which the springarrangement of FIG. 2 is integrated;

FIG. 5 shows a conventional perspective of an arrangement of independentbag-lined springs that forms an integral part of the protected inventionin the patent MX352.312B, where it is possible to appreciate a retentionand isolation band that surrounds the arrangement of springs, and alayer of support material or background;

FIG. 6 shows a conventional perspective of the arrangement of springs ofFIG. 5, when said arrangement is arranged on the layer of supportmaterial or background;

FIG. 7 shows a top plan view of the spring core of the inventionprotected in the patent MX352.312B;

FIG. 8 shows a conventional perspective of an arrangement of independentbag-lined springs disposed on a layer of support material or background,both elements forming an integral part of the proposed invention.

FIG. 9 shows a conventional perspective of a bag-lined spring core withmonolithic perimeter frame and reinforced and stabilized edges, made inaccordance with the present invention;

FIG. 10 shows a conventional perspective illustrating in detail section“A” of FIG. 9;

FIG. 11 shows a top plan view of the bag-lined spring core withmonolithic perimeter frame and reinforced and stabilized edges of FIG.9;

FIG. 12 shows a top plan view illustrating in detail section “B” of FIG.11;

FIG. 13 shows a front elevation view of a section of the bag-linedspring core with monolithic perimeter frame and reinforced andstabilized edges of FIG. 9, where the arrangement of a loading press inits upper position is appreciated, press to from which tests of pressureand deformation were carried out at the edges of the core; Y

FIG. 14 shows a front elevation view of a core section of bag-linedsprings with monolithic perimeter frame and reinforced and stabilizededges of FIG. 9, wherein the arrangement of the loading press in itslower position is seen.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

As mentioned above, the present utility model is the result of astructural modification in the configuration of the invention protectedin the patent MX352,312B, modification that results in substantialimprovements in strength and stability at the edges of a core of springswith monolithic perimeter frame, a condition that is achieved from thejoint work of two elements that integrate said core springs, namely: theperipheral bag-lined springs of the core of springs; and a monolithicperimeter frame formed in situ. The integration of both elements intoone is achieved when the foaming material from which the monolithicperimeter frame is formed in-situ adheres to each of the bags containingthe springs that together define the periphery of the spring core.

In this order of ideas, prior to describing the technicalcharacteristics that together define the proposed utility model, a briefdescription of the protected invention in the following is disclosedbelow and based on what is illustrated in FIGS. 1 to 7, referred toMexican patent, property of applicant requesting the presentregistration of the present utility model.

The invention described, illustrated and protected in the patentMX352,312B, consists of a core of springs with monolithic perimeterframe 100 used in the manufacture of seats for furniture or mattresses,which is comprised of: an arrangement of springs 10, a band of retentionand insulation 30 made of woven or non-woven fabric or similar materialsurrounding the arrangement of springs 10 and whose height is coincidentwith that of the arrangement; a layer of support or bottom material 20on which the arrangement of springs 10 is arranged and a surface 22 isdefined on which a perimeter frame rests; and a monolithic perimeterframe 40 made in situ of foaming material which surrounds and reinforcesthe arrangement of springs 10 which is firmly attached as part of thechemical reaction of its foaming process and adhesion to both thesupport material 20 and the retaining band and insulation 30.

In one embodiment of this Mexican patent, it has been defined that thearrangement of springs 10 can be made from bag-lined independent springsas shown in FIGS. 2, 3 and 4, where each of the springs 12 that definesthe arrangement 10, is placed inside a sealable bag 14 which in turn isattached to other sealable bags 14 by means of an adhesive, or by aseam, or even by electronic sealing, and in this embodiment of theinvention, the shape, separation and dimensions of the arrangement ofsprings 10, obeys in its entirety to the predefined itself for thearrangement of bags 14 that contain them, this being the same as thedimensions of length, width and height of the measurements of thefurniture seat or mattress that you want to manufacture. The bags 14used to introduce each of the springs 12 of the arrangement 10 arepreferably made of woven or non-woven fabric, but may be constructedfrom a variety of other materials, including, but not limited to, paper,plastic, or other materials flexible permeable or waterproof.

In the embodiment of the arrangement of springs 10 made from independentbag-lined springs 12, each of the springs 12 which are preferably of thecylindrical type, is separated from the other springs 12 of thearrangement at a uniform distance, however, in other embodiments of thisinvention, it is established that the springs 12 can be arranged inarrangements of irregular separations, for example, if a variation inthe amount of the support is desired through the surface of thefurniture or mattress seat that is manufactured.

From the illustrated details in FIGS. 3 and 4, it is possible to seethree sealable bags 14 joined together, of the type that are preferablyused in the invention protected by the patent MX352,312B for bagginginside to each of the springs 12 that as a whole, define the arrangementof springs 10, wherein, each of the sealable bags 14 are joined togetherto form a desired array of sealable bags 14 by means of a thermaladhesive 16 which is applied over the joint flanges 15 which form anintegral part of each of said sealable bags 14. Although it should bekept in mind that as previously indicated, the connection can be bymeans of a seam, or even by electronic sealing.

In the core of springs with monolithic perimeter frame 100 of theMexican patent, the retaining band 30 that surrounds the arrangement ofsprings 10, allows on the one hand, to preserve the alignment andarrangement previously determined for said arrangement 10, and on theother hand, preventing the foaming material with which the monolithicperimeter frame 40 surrounding and reinforcing said arrangement 10 isbuilt in situ, penetrates and undesirably solidifies in the empty spacesdefined between the bag-lined springs 12, reason why which band 30 ismade of woven or nonwoven materials similar to those referred to abovefor the sealable bags 14, with the particularity that preferablyimpermeable materials are used in it.

The monolithic perimeter frame 40 made of foam material which surroundsand reinforces the arrangement of bag-lined springs 10, is formed insitu on the surface 22 defining the surplus material of the supportlayer 20 and around the arrangement of springs 10, having as penetrationbarrier towards said arrangement of springs 10 to the retaining andinsulating band 30, and as a result of a chemical reaction of thefoaming material from which it is manufactured, said perimeter frame 40adheres firmly to both the surface 22 of the material of support 20 asto the retaining band 30, and in the case of using the retention andisolation band 30 with a plurality of holes 31, to the bags 14containing all the peripheral springs 12 of the spring arrangement 10.In the same patent, it is noted that the penetration of the foamingmaterial through the holes 31 of the retaining and insulation band 30towards the bags 14 of the peripheral springs 12 is minimal and barelysufficient to join the foaming material with said bags 14.

The patent MX352,312B also protects a process for manufacturing the coreof springs with monolithic perimeter frame 100, which is perfected froman injection mold or emptying capable of housing inside asemi-determined core of springs with the dimensions and proper forms oflength, width and height of a furniture and mattress seat that isrequired to satisfy a specific need, wherein, said mold comprisesarranged around its periphery various sectioned lid elements that from amovement of turning allow to define an open mold or closed moldposition, so that elements such as staples, presses or clamps allow toensure the closed mold position, in the understanding that the releaseor withdrawal of said elements allows transit to the position of openmold by freely rotating the lid elements; process that generallycomprises the following stages:

a) surrounding a spring arrangement previously made with a retainingband and insulation whose height is coincident with that of thearrangement of springs and on which are configured a plurality of holes,through which a foaming material with which a perimeter frame is able topenetrate the band in the direction of the arrangement of springs,

b) arranging the arrangement of springs surrounded by the retaining bandand insulation on a layer of support material inside the injection orcasting mold;

c) injecting through a mixing nozzle and injector foaming material, ormanually empty a mixture for flexible foam polyurethane or any otherfoaming material desired to the interior of the mold for injection oremptying in the space comprised between the retaining band andinsulation surrounding the arrangement of springs and the side walls ofsaid mold;

d) rotating the various sectioned lid elements of the injection orcasting mold from its open mold position to that of closed mold once theinjection or emptying of stage c) has been performed on each sectioncorresponding to one of the various elements of injection mold cap oremptying;

e) securing the closed mold position in each of the various lid elementsfrom the elements that allow securing this position, such as staples,presses or clamps;

f) wait long enough for the liquid foam injected or emptied to cure andconvert to the solid state, thus forming the monolithic reinforcingperimeter around the arrangement of springs that has been obtained fromthe previous stages;

g) releasing or removing the elements that allow to ensure the closedmold position;

h) rotating the various sectioned lid elements of the injection oremptying mold from its closed mold position to that of open mold;

and

i) removing the spring arrangement from the inside of the injection oremptying mold, which is now attached to a monolithic reinforcementperimeter frame.

From the above information and the one that can be seen from the Mexicanpatent of reference, it is possible to notice that in the inventionprotected in it, with the retaining band and insulation 30 it is soughtto prevent from penetrating into the arrangement of springs 10 thefoaming material with which the monolithic perimeter frame 40 is builtin situ, that is, in the invention known today, the contact of thefoaming material surrounding and reinforcing the arrangement of springs10 is limited both to the support material 20 and to the retention andinsulation band 30, a condition that technically implies an independentoperation of both the monolithic perimeter frame 40 and the arrangementof springs 10 contained therein.

The technical contribution of the present utility model, consists ofachieving a joint operation of the arrangement of springs 10 and themonolithic perimeter frame 40, said joint operation that allows tosupport greater efforts of continuous loading, in particular, at theedges of the resulting core, condition which is achieved by suppressingor eliminating from the spring core 100 the retention band andinsulation 30 that of origin prevents or limits the penetration of thefoaming material towards the arrangement of springs.

In the proposed utility model, the effect of stabilizing and increasingthe structural strength of the edges of a bag-lined spring core with amonolithic perimeter frame is achieved by eliminating the retention andinsulation band 30, in such a way that shown in FIGS. 8 and 9, thearrangement of bag-lined springs 10′ is arranged directly on a layer ofsupport material or bottom 20′ from which a surface 22′ is defined onwhich a monolithic perimeter frame 40′ will be formed in situ and aroundof said arrangement of bag-lined springs 10′.

In this way, when the retaining and insulation band 30 is removed,during the forming process of the monolithic perimeter frame 40′ made insitu, the foaming material surrounding and reinforcing the springarrangement 10′ will now be firmly attached as part of the chemicalreaction of your foaming process and adhesion both to the supportmaterial 20′ and to each of the bags containing the peripheral springsof the core, said foaming material also penetrating, in each of theempty spaces that are defined between each of the bags containing theperipheral springs of spring arrangement 10′.

According to what is illustrated in FIGS. 9 to 12, with the proposed newconfiguration, it is achieved that the monolithic perimeter frame 40′formed in situ, penetrates into the empty spaces that are definedbetween each of the bags containing the peripheral springs of the springarrangement 10′ and having the possibility of coming into direct contactwith each of said bags, work together with the arrangement of springs.With this new configuration it is achieved that the monolithic perimeterframe 40′ embraces each peripheral bag in at least a portion close to50% of its circumference, while, in the case of the bags containing thesprings defining each of the four corners of the spring arrangement, theportion surrounded by the monolithic perimeter frame 40′ is close to 75%of its total circumference.

Based on the foregoing, it is possible to establish that the presentutility model consists of a bag-lined spring core with monolithicperimeter frame and reinforced and stabilized edges 100′ used in themanufacture of seats for furniture or mattresses, which is comprised of:arrangement of springs 10′; a layer of support material or bottom 20′ onwhich the arrangement of springs 10′ is arranged and a surface 22′ onwhich a perimeter frame rests; and a monolithic perimeter frame 40′ madein situ of foaming material which surrounds, reinforces and bonds firmlyas part of the chemical reaction of its foaming and adhesion processboth to the support material 20′ and to each of the bags containing theperipheral springs of the nucleus.

It should be mentioned that the new configuration of the bag-linedspring core with monolithic perimeter frame and reinforced andstabilized edges 100′ that is proposed, is not intended to claimprotection for the fact of having removed the retention and isolationband 30 from the core of the patent MX352,312B, but for the technicaleffect of making the peripheral springs of the spring arrangement 10′work in combination with the monolithic perimeter frame 40′ to withstandcompressive stresses whose magnitude could cause permanent or prematuredeformations to both the peripheral springs and the monolithic perimeterframe 40′ if these will support them independently.

In this regard it must be said that the solidifying effect of thefoaming material around the bags 14′ containing the peripheral springsof the spring arrangement 10′ integrates these two elements into one, acondition that, in itself, increases the load resistance that bothelements could have it in isolation.

In a preferred embodiment of the present utility model, the foamingmaterial with which the monolithic perimeter frame 40′ is constructedresults, but is not limited to, a mixture for flexible polyurethanefoam.

In order to check the stability and increase of the structural strengthat the edges of the proposed new core, said core has been subjected tostress and fatigue tests, in particular, as shown in FIGS. 13 and 14,the edges of the core were subjected with the help of a loading press200 with a cycle of 1000 repetitions applying a dead load between 75 kgand 100 kg. The results obtained demonstrated, on the one hand, that theunion between the monolithic perimeter frame 40′ and the bags 14′containing the peripheral springs of the spring arrangement 10′stabilizes and increases the structural strength of the edges of theproposed core, and on the other, that the resistance to fatigue anddeformation both of the peripheral springs of the spring arrangement 10′and of the monolithic perimeter frame 40′ is greater when both elementsare firmly joined and work together.

On the other hand, it should be mentioned that the present utility modelcan be manufactured from the process claimed in the patent MX352.312B,for which purpose step (a) must be omitted, which consists in enclosinga previously prepared arrangement of springs with a band of retentionand isolation, and in relation to step b) should be arranged directlythe arrangement of springs on a layer of support material inside themold of injection or emptying, that is, without that arrangement issurrounded by a band of retention and isolation, stages c) to i) do notundergo any modification and together with them it is possible to obtainthe new proposed nucleus.

According to all the previously described and illustrated, it ispossible to notice that the invention proposed as a “bag-lined springcore with monolithic perimeter frame and reinforced and stabilizededges”, offers a practical, efficient and economic solution to overcomethe current inconveniences in the technical field to which it belongs,specifically those that refer to prevent premature deformation of boththe springs arranged on the periphery of a core of springs, or the ownperimeter frame of foaming material.

What is claimed is:
 1. A core of springs with monolithic perimeter frameand reinforced and stabilized edges, of the type used for themanufacture of seats for furniture or mattresses, comprising: anarrangement of independent bag-lined cylindrical springs; and a layer ofsupport material or bottom on which the arrangement of springs isarranged, being the dimensions in length and width of said layer ofsupport material greater than those of the arrangement of springs,thereby generating a surplus of material around the arrangement ofsprings that supports, which is characterized in that; a monolithicperimeter frame of foamed material made in situ on the surplus materialof the support layer, surrounds and reinforces the arrangement ofsprings, so that said perimeter frame is firmly joined as part of thechemical reaction of its foaming and adhesion process both to thesupport material and to each of the bags containing the peripheralsprings of the core, wherein said perimeter frame also penetrates eachof the empty spaces defined between each of the bags containing theperipheral springs of the arrangement of springs.
 2. The core of springswith monolithic perimeter frame and reinforced and stabilized edges, asclaimed in claim 1, characterized in that; the monolithic perimeterframe surrounds each of the bags containing the peripheral springs in atleast a portion close to 50% of its circumference.
 3. The core ofsprings with monolithic perimeter frame and reinforced and stabilizededges, as claimed in claim 1, characterized in that; the monolithicperimeter frame surrounds each of the bags that contain the cornersprings of the arrangement of springs in at least a portion close to 75%of its circumference.
 4. The core of springs with monolithic perimeterframe and reinforced and stabilized edges, as claimed in claim 1,characterized in that; the foaming material with which the monolithicperimeter frame is built in situ results, but is not limited to, amixture for flexible polyurethane foam.